Question 1

What is FMEA?

Accepted Answer

FMEA (Failure Mode and Effects Analysis) is a systematic method for identifying potential failure modes in a system, process, or piece of equipment. For each failure mode, FMEA evaluates the severity of the effect, the likelihood of occurrence, and the ability to detect the failure before it reaches the end user. These three factors are multiplied to produce a Risk Priority Number (RPN) that helps maintenance and reliability teams prioritize corrective actions. Originally developed by the U.S. military in the 1940s and later adopted by the automotive industry through AIAG standards, FMEA is now widely used across manufacturing, aerospace, healthcare, and energy sectors.

Question 2

How is RPN calculated?

Accepted Answer

RPN (Risk Priority Number) is calculated by multiplying three factors: Severity (S), Occurrence (O), and Detection (D). Each factor is rated on a scale of 1 to 10. Severity measures how serious the effect of the failure would be (1 = negligible, 10 = catastrophic). Occurrence measures how likely the failure is to happen (1 = extremely unlikely, 10 = almost certain). Detection measures how likely the failure is to be caught before it causes harm (1 = almost certain to detect, 10 = virtually undetectable). The formula is RPN = S x O x D, producing a value between 1 and 1,000. Higher RPN values indicate higher risk and should be addressed first.

Question 3

What equipment types are supported?

Accepted Answer

This FMEA generator includes pre-built failure mode templates for six common industrial equipment types: Motors (bearing failure, winding burnout, shaft misalignment, overheating, VFD faults, insulation breakdown, coupling failure, foundation loosening), Pumps (seal failure, cavitation, impeller wear, suction issues, coupling failure, bearing damage, casing corrosion, shaft deflection), Compressors (valve failure, oil contamination, pressure loss, excessive vibration, overheating, belt wear, filter clogging, refrigerant leak), Gearboxes (gear tooth wear, bearing failure, oil degradation, seal leakage, misalignment, overloading, backlash increase, housing crack), Conveyors (belt misalignment, roller bearing failure, motor overload, belt splice failure, take-up adjustment, idler seizure, chain stretch, pulley lagging wear), and HVAC systems (compressor failure, refrigerant leak, fan motor burnout, coil fouling, thermostat malfunction, filter restriction, duct leakage, drain blockage). You can also add custom failure modes for any equipment type.

FMEA Generator

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Frequently Asked Questions About FMEA

What is FMEA?

How is RPN calculated?

What equipment types are supported?